Cold formed stud

ABSTRACT

A cold formed metal stud is provided for commercial and residential construction applications. The metal stud of the present invention is suitable for use in both composite and non-composite applications. The metal stud of the present invention includes an intermediate web, a first flange and a second flange. The first flange has a longitudinally extending channel. Each of the intermediate web, first flange and second flange may include a number of different design features that can increase the structural and heat transfer characteristics of the metal stud.

CROSS-REFERENCE TO RELATED APPLICATION

This is a continuation-in-part of co-pending application Ser. No.12/868,806 filed on Aug. 26, 2010.

FIELD OF THE INVENTION

The present invention relates to cold formed metal studs for compositeand non-composite applications in residential and commercialconstruction projects.

BACKGROUND OF THE INVENTION

Studs are commonly used in the construction industry to provide asupport for a wall surface and further support a roof, a floor or thelike. Studs can be comprised of a variety of materials including woodand metal. Metal studs are commonly used in a variety of constructionstyles as they can be manufactured economically and are light, strongand durable.

Metal studs are commonly fashioned from a piece of sheet metal that iscold formed to desired specifications. Cold forming involves working amaterial below its recrystallization temperature. Generally, coldforming occurs at the ambient temperature of the work environment. Theresultant cold formed material is stronger due to manipulations thathave been made to the crystal structure of the material. Cold forming isan economical manufacturing process as it does not require thesignificant energy input required to raise the material above itsrecrystallization temperature. Cold forming has the further advantage ofproviding steel structural components that have increased yield capacityin comparison to steel structural components that have not been coldformed.

Pre-fabricated metal studs are well-known in the construction industry.However, there is a distinct lack of metal studs that have beenspecifically designed for use with both composite and non-compositeapplications.

Therefore, there is need for a prefabricated metal stud for use incomposite and non-composite applications that is light, strong, durableand economically manufactured and can be readily modified depending onthe needs of various applications.

BRIEF SUMMARY OF THE INVENTION

The present invention provides a cold formed stud for use in compositeand non-composite applications.

In at least one embodiment, the present invention provides a cold formedmetal stud having a vertically extending web, the web having a firstlongitudinal edge and a second longitudinal edge, a first flange portionvertically extending along the first longitudinal edge, the first flangeportion having a vertically extending channel and a second flangeportion vertically extending along the second longitudinal edge.

In at least one embodiment, the present invention provides a double studarrangement wherein two studs are aligned back-to-back in order toprovide a stud that is particularly resistant to buckling and twisting.

The present invention also provides a method of forming a compositepanel assembly consisting of the steps of pouring a concrete panel andembedding a first flange portion of a cold formed metal stud in theconcrete panel, the first flange portion located along a firstlongitudinal edge of a vertically extending web of the cold formed metalstud such that when the concrete panel solidifies the cold formed metalstud and the concrete panel form a composite panel assembly.

In at least one embodiment, the present invention provides a cold formedstud that can be employed as a ceiling joist. In such applications, thecold formed joist of the present invention can be embedded in acomposite ceiling or floor panel.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the present invention will now be described ingreater detail and will be better understood when read in conjunctionwith the following drawings in which:

FIG. 1 is a rear perspective view of a cold formed metal stud inaccordance with at least one embodiment of the present invention;

FIG. 2 is a front perspective view the cold formed metal stud of FIG. 1;

FIG. 3 is an end elevational view of the cold formed metal stud of FIG.1;

FIG. 4 is a top plan view of the cold formed metal stud of FIG. 1;

FIG. 5 is a rear side elevational view of the cold formed metal stud ofFIG. 1;

FIG. 6 is an opposite end elevational view of the cold formed metal studof FIG. 1;

FIG. 7 is a front perspective view of a cold formed metal stud inaccordance with another embodiment of the present invention;

FIG. 8 is a rear perspective view of the cold formed metal stud of FIG.7;

FIG. 9 is an end elevational view of the cold formed metal stud of FIG.7;

FIG. 10 is a top plan view of the cold formed metal stud of FIG. 7;

FIG. 11 is a front side elevational view of the cold formed metal studof FIG. 7;

FIG. 12 is an opposite end elevational view of the cold formed metalstud of FIG. 7;

FIG. 13 is a partial perspective sectional view of the cold formed metalstud of FIG. 7 with modifications embedded in a concrete panel;

FIG. 14 is a partial end view of the cold formed metal stud of FIG. 13embedded in the concrete panel;

FIG. 15 is a rear perspective view of a cold formed metal stud inaccordance with another embodiment of the present invention;

FIG. 16 is a front perspective view of the cold formed metal stud ofFIG. 15;

FIG. 17 is a rear perspective view of a cold formed metal stud inaccordance with another embodiment of the present invention;

FIG. 18 is a front perspective view of the cold formed metal stud ofFIG. 17;

FIG. 19 is a front perspective view of a double stud arrangement inaccordance with another embodiment of the present invention; and

FIG. 20 is a cross-sectional view of the double stud of FIG. 19 embeddedin a concrete panel.

DETAILED DESCRIPTION OF THE INVENTION

The cold formed stud of the present invention is contemplated for use incomposite and non-composite applications. In composite applications, thecold formed joist can be incorporated directly in a poured concrete wallslab in a manufacturing facility and delivered to the jobsite as acomplete assembly for wall erection, among other applications. Thecomposite arrangement provides an integral wall panel and stud assemblythat displays excellent strength characteristics, vibration response andload capacity, without unduly stressing the poured concrete wall panel.It is also contemplated that in certain applications, the integral wallpanel and stud assembly may be assembled at the jobsite after the coldformed joist has been installed. Composite applications will bediscussed in further detail below.

In at least one embodiment, the cold formed stud of the presentinvention is incorporated in a concrete wall slab as discussed above.However, it is further contemplated that the cold formed stud of presentinvention can be incorporated in wall slabs formed out of othermaterials, such as but not limited to fibreglass, polymer resin andother materials that “set” following an initially liquid state, as willbe readily understood by the skilled person.

It is contemplated that the cold formed stud of the present inventionmay also be used as a ceiling joist in particular applications that willbe readily recognized by the skilled person. Particularly, the coldformed stud of the present application may be employed in applicationswherein the ceiling joist is subjected to relatively lightweight loads.In these applications, the cold formed stud may be embedded in acomposite roof or floor panel in a manner that is analogous to theprocess described above relating to composite wall panels.

FIGS. 1 to 20 illustrate a cold formed stud 10 in accordance with atleast one embodiment of the present invention. In these figures, likenumerals have been used to denote like elements. Referring initially toFIGS. 1 and 2 and 7 and 8, cold formed stud 10 consists of anintermediate web 20 located between a first flange 30 and a secondflange 40. Preferably, cold formed stud 10 is formed from a single pieceof sheet metal. The sheet metal may be formed by any process known inthe art such as cold rolling and stamping, among other processes thatwill be readily apparent to the skilled person.

The size and thickness of the piece of sheet metal used in manufacturingcold formed stud 10 must be sufficient such that the resulting elementhas the physical properties required for the intended application, theselection of which will be readily apparent to the skilled person in theart. Cold formed stud 10 can be formed of a variety of metals, such asbut not limited to steel, stainless steel, galvanized steel andaluminum. Cold formed stud 10 may be formed in various lengths andwidths.

Stud 10 can extend upwardly from any foundation or floor structure,among other construction applications that will be readily apparent tothe skilled person. Stud 10 can be attached to the foundationalstructure by any means that is suitable. Further, the stud can support aroof truss, floor joist or any other structure that will also beapparent to the skilled person. It can also support an exterior wallpanel, interior wall panel, window frame, door frame or any other wallarrangement known in the construction industry.

In at least one embodiment, intermediate web 20 includes a number of webopenings 22 located along the centre line of the intermediate web 20.Web openings 22 can take a variety of shapes including triangular,square, oval, circular and other shapes that will be readilycontemplated by the skilled person. It is important to note however thatweb openings 22 will provide further stiffness to intermediate web 20and be less prone to fatigue failure if the corners of web openings 22are formed with rounded corners rather than sharp corners, as can beseen in FIGS. 5, 11 and 15 to 18.

In at least one embodiment, web openings 22 can further include astiffening rim 24 that extends around the perimeter of web openings 22.Stiffening rim 24 is formed of material displaced from intermediate web20 when web openings 22 are formed. Stiffening rim 24 can be formed witha semi-circular, arcuate, ovular, or square cross sectional profileamong other cross-sectional profiles that will be readily apparent tothe skilled person. Stiffening rim 24 may extend discontinuously aroundthe perimeter of web opening 22, however stiffening rim 24 will provideimproved stiffness to intermediate web 20 and be less prone to fatiguefailure if stiffening rim 24 extends continuously around the perimeterof web openings 22, as can be seen in FIGS. 1, 2, 7, 8 and 15 to 18.

In at least one embodiment, intermediate web 20 can further include aseries of longitudinally extending stiffening ribs 26, as can be seen inFIGS. 7, 8, 11, 17 and 18. Longitudinally extending stiffening ribs 26can extend along the intermediate web 22 in any pattern that will dependupon the arrangement of other features of the present invention. In atleast one embodiment and as can be seen in FIGS. 7, 8, 11, 17 and 18,longitudinally extending ribs 26 extend in a zig-zag pattern along theupper and lower edges of intermediate web 20 such that longitudinallyextending ribs 26 extend parallel in the areas between web openings 22and the edges of intermediate web 20 and extend angularly toward thecentreline of the intermediate web 20 in areas where there is no webopening. Additional stiffening ribs 26 can also be located in the endsof cold formed stud 10 as can be seen in FIGS. 7, 8, 11, 16 and 18.

In at least one embodiment, intermediate web 20 can further include aseries of stiffening indentations 28 that can be located in any part ofintermediate web 20 that can require additional stiffening, as can beseen in FIGS. 2, 5, 7, 8, 16 and 18. In at least one embodiment,stiffening indentations 28 are located in the area between the angledportions of longitudinally extending stiffening ribs 26. Stiffeningindentations 28 can be formed in any shape, including circular, square,rectangular or any other shape that will be readily apparent to theskilled person. As discussed above, stiffening indentations 28 can beformed with rounded edges to provide further resistance to fatiguefailure.

In at least one embodiment, intermediate web 20 can further include aseries of transverse stiffening ribs 29 that can that can be located inany part of intermediate web 20 that can require additional stiffening,as can be seen in FIGS. 17 and 18. In at least one embodiment,transverse stiffening ribs 29 are located between adjacent web openings22. Stiffening ribs 29 are analogous to stiffening indentations 28 inthat they can be formed in any shape, including circular, square,rectangular or any other shape that will be readily apparent to theskilled person. As discussed above, stiffening ribs 29 can be formedwith rounded edges to provide further resistance to fatigue failure.

Web openings 22, stiffening rim 24, longitudinally extending stiffeningribs 26, stiffening indentations 28 and transverse stiffening ribs 29can be formed by any suitable manufacturing processes includingstamping, milling and rolling, among other manufacturing processes thatwill be readily apparent to the skilled person. In addition to providingstiffness to stud 10, these additional features also serve to reduce theheat transfer characteristics of stud 10. By this it is meant that thesefeatures reduce the rate at which the stud conducts heat for improvedheating or cooling of a space at least partially enclosed by structuresthat incorporate studs 10.

As discussed above, first flange 30 is formed along one longitudinaledge of intermediate web 20, as seen in FIGS. 1, 2, 7, 8, 16 and 18. Inat least one embodiment, first flange 30 is oriented perpendicularly tointermediate web 20, however it is contemplated that first flange 30 canbe oriented at any angle in relation to intermediate web 20 depending onthe needs of the application.

With reference to FIGS. 1, 2, 7, 8, 13 and 15 to 18, first flange 30 caninclude an end flange 32. End flange 32 can be oriented perpendicularlyto first flange 30 however it is contemplated that end flange 32 can beoriented at any angle in relation to first flange 30 as required by theapplication.

As can be seen in FIGS. 1 to 4, 6, 7 to 10, 12 and 15 to 18, firstflange 30 can include a longitudinally extending channel 34 that islocated along the centre line of first flange 30. As can be seen inFIGS. 3, 6, 9 and 12, it is contemplated that channel 32 has channelwalls that are orthogonal to the channel floor when viewed in crosssection, however channel 34 can take any cross-sectional shape asrequired by the application, such as triangularly shaped, U-shaped ordovetail shaped as will be appreciated by the skilled person.Longitudinally extending channel 34 provides stiffness to first flange30 and also provides a cavity wherein concrete, polymer resin orfibreglass can be poured thereinto such that first flange 30 can besecurely embedded in a concrete panel when cold formed stud 10 isemployed in composite applications, as will be discussed in furtherdetail below.

First flange 30, end flange 32 and channel 34 can be formed by anysuitable manufacturing process that will be readily apparent to theskilled person. Further, first flange 30, end flange 32 and channel 34can be formed with any type of bend that suits the application, howeverradial bends provide a cold formed stud that has the requisite stiffnessand fatigue resistance.

In at least one embodiment and as can be seen in FIG. 10 for example,channel 34 can include a series of perforations 36 located on thechannel floor. Perforations 36 can extend along the entire length ofchannel 34 or alternatively can be located on only a section of channel34. In at least one embodiment perforations 36 are ovoid or ellipticallyshaped, however it is contemplated that perforations 36 can take anyshape that suits the intended application. Perforations 36 serve anumber of purposes including providing a thermal break which facilitatesheat dissipation from cold formed stud 10. Further, in compositeapplications, perforations 36 allow first flange 30 to be integrallyembedded in concrete by allowing liquid concrete, polymer resin orfibreglass to fill the entire volume of channel 34 without creating anyair bubbles within channel 34.

In at least one embodiment and as can be seen in FIGS. 4, 16 and 18,channel 34 can include a series of indentations 38 located on thechannel floor. Indentations 38 can extend along the entire length ofchannel 34 or alternatively can be located on only a section of channel34. In at least one embodiment perforations 36 are ovoid or ellipticallyshaped, however it is contemplated that perforations 36 can take anyshape that suits the intended application.

As can be seen in FIGS. 1, 2, 7, 8, 15 and 17 second flange 40 isanalogous to first flange 30 and can incorporate some or all thefeatures recited above in relation to first flange 30. In this way,second flange 40 may include an end flange 42, a channel 44,perforations 46 and/or indentations 48 depending on the needs of theapplication.

As can be seen in FIGS. 13 and 14, the present invention may be utilizedin composite applications to produce a composite stud/panel assemblywherein the stud component is lighter and stiffer in comparison tosimilar non-composite stud arrangements. As will be appreciated, inthese views, only one of the stud's flanges 30 or 40 is shown as is onlya small portion of web 20. The remainder of the stud 10 is not shown forclarity. As discussed above, either one or both of first flange 30 orsecond flange 40 can be adapted with any of the optional featuresidentified above such that either flange can be securely embedded in aconcrete panel 50. These features include end flange 32, channel 34,perforations 36 and/or indentations 38, all of which can be adapted ormodified depending on the needs of the particular composite application.

For example and as can be seen in FIGS. 13 and 14, cold formed stud 10can designed with a second flange 40 having an end flange 42 that isoriented at an obtuse angle to second flange 40. Further, second flange40 can be designed with a channel 44 that has a slightly dove shapedprofile for an improved “lock” with the concrete to prevent lateralseparation, channel 44 having a series of perforations 46 located alongthe floor of channel 44. Perforations 46 can take any shape and can beformed by any suitable manufacturing process. Perforations 46 can be asnumerous as required by the application. As also discussed above,intermediate web 20 can have stiffening rib 26 which can also bepartially embedded in concrete panel 50. In this way, cold formed stud10 is securely embedded in concrete panel as concrete flows throughperforations 46 and completely fills channel 44 without trapping any airbubbles, resulting in a composite stud/panel assembly that has improvedstructural characteristics over existing composite designs.

In at least one embodiment, cold formed stud 10 (which can include theoptional features recited above such as web openings 22, stiffening rim24, longitudinally extending stiffening ribs 26, stiffening indentations28, transverse stiffening ribs 29, end flange 32, channel 34,perforations 36 and/or indentations 38) can be specifically designedsuch that the cross sectional area is constant at all locations alongcold formed stud 10.

With reference to FIGS. 5 and 11, cold formed stud 10 can be designedsuch that the cross sectional area of the stud at section A-A, B-B andC-C is approximately equivalent. In embodiments where thecross-sectional area of cold formed stud 10 is constant at any pointalong the length of the stud, it will be understood that relatedstructural properties, such as the moment of inertia and the sectionmodulus of the stud will also be constant at any point along the lengthof the stud. This results in a structural element that is stronger,stiffer and more resistant to compressive and torsional forces, as willbe readily understood by the skilled person in the art.

With reference to FIGS. 19 and 20, in at least one embodiment a doublestud arrangement is contemplated that is well suited to applicationswhere the stud is subjected to particularly high loads. Double stud 100includes a first cold formed stud 102 and a second cold formed stud 104that are analogous to cold formed stud 10 and can include any of thefeatures identified above with respect to a single cold formed stud.First cold formed stud 102 and second cold formed stud 104 are arrangedsuch that the intermediate webs of each stud abut one another. In atleast one embodiment, the two cold formed studs are symmetrical andaligned such that the web openings on first cold formed stud 102 alignwith the web openings of second cold formed stud 104, as seen in FIG.19.

In at least one embodiment and as can be seen in FIG. 19, it iscontemplated that each of first cold formed stud 102 and second coldformed stud 104 can have a plurality of vertical stiffening ribs 106.Stiffening ribs 106 are analogous to longitudinally extending stiffeningribs 26 with the exception that stiffening ribs are orthogonallyoriented in relation to the longitudinal axis of the stud to providetorsional stiffness to the resultant double stud 100.

In at least one embodiment the two studs are connected by way of a bolt108, however other fasteners are also contemplated such as welds,rivets, and sheet metal screws among other fasteners that will bereadily apparent to the skilled person.

It is contemplated that double stud 100 may also be used as a ceilingjoist in particular applications that will be readily recognized by theskilled person. In these applications, double stud 100 may be embeddedin a composite roof or floor panel in a manner that is analogous to theprocess described above relating to composite wall panels.

The above-described embodiments of the present invention are meant to beillustrative of preferred embodiments of the present invention and arenot intended to limit the scope of the present invention. Variousmodifications, which would be readily apparent to one skilled in theart, are intended to be within the scope of the present invention. Theonly limitations to the scope of the present invention are set out inthe following appended claims.

We claim:
 1. A cold formed metal stud, the stud comprising: a verticallyextending web, said web having a first longitudinal edge and a secondlongitudinal edge; a first flange portion vertically extending alongsaid first longitudinal edge, said first flange portion having avertically extending channel; and, a second flange portion verticallyextending along said second longitudinal edge.
 2. The cold formed metalstud of claim 1, said channel having at least one channel perforation.3. The cold formed metal stud of claim 1, said channel having at leastone channel indentation.
 4. The cold formed metal stud of claim 1, saidchannel having a dovetail shaped cross-sectional profile.
 5. The coldformed metal stud of claim 1, wherein said first flange portion isembedded in a poured concrete panel.
 6. The cold formed metal stud ofclaim 1, wherein said second flange portion is embedded in a pouredconcrete panel.
 7. The cold formed metal stud of claim 1, said webfurther comprising at least one web opening located along the centerlineof said web.
 8. The cold formed metal stud of claim 7, said at least oneweb opening being elliptically shaped.
 9. The cold formed metal stud ofclaim 7, said at least one web opening having a stiffening rim extendingaround the perimeter thereof.
 10. The cold formed metal stud of claim 1,said web further comprising at least one longitudinally extendingstiffening rib.
 11. The cold formed metal stud of claim 10, saidstiffening rib being shaped in a zig-zag pattern.
 12. The cold formedmetal stud of claim 1, said web further comprising at least oneindentation.
 13. The cold formed metal stud of claim 1, said web furthercomprising at least one vertical stiffening rib.
 14. The cold formedmetal stud of claim 1, said first flange further comprising an endflange.
 15. The cold formed metal stud of claim 1, said first flangeforming an obtuse angle with said web.
 16. The cold formed metal stud ofclaim 1, said first flange forming an acute angle with said web.
 17. Thecold formed metal stud of claim 1, said second flange forming an obtuseangle with said web.
 18. The cold formed metal stud of claim 1, saidsecond flange forming an acute angle with said web.
 19. The cold formedmetal stud of claim 1, said second flange further comprising avertically extending second channel.
 20. The cold formed metal stud ofclaim 19, said second channel having a dovetail shaped cross-sectionalprofile.
 21. The cold formed metal stud of claim 19, said second channelhaving a plurality of channel perforations.
 22. The cold formed metalstud of claim 19, said second channel having a plurality of channelindentations.
 23. The cold formed metal stud of claim 1, said secondflange further comprising an end flange.
 24. A method of forming acomposite panel assembly, the method comprising the steps of: pouring aconcrete panel; and, embedding a first flange portion of a cold formedmetal stud in said concrete panel, said first flange portion locatedalong a first longitudinal edge of a vertically extending web of saidcold formed metal stud wherein when said concrete panel solidifies saidcold formed metal stud and said concrete panel form a composite panelassembly.
 25. A method of manufacturing a cold formed metal stud, themethod comprising the steps of: forming a first flange portion along afirst longitudinal edge of a vertically extending web; forming a secondflange portion along a second longitudinal edge of said verticallyextending web; and forming a vertically extending channel along saidfirst flange portion.
 26. The method of claim 25, the method furthercomprising the step of: forming at least one channel perforation in saidvertically extending channel.
 27. The method of claim 25, the methodfurther comprising the step of: forming at least one channel indentationin said vertically extending channel.
 28. The method of claim 25, themethod further comprising the step of: forming at least one web openingalong the centerline of said web.
 29. The method of claim 28, whereinsaid at least one web opening is elliptically shaped.
 30. The method ofclaim 28, the method further comprising the step of: forming astiffening rim around the perimeter of said at least one web opening.31. The method of claim 25, the method further comprising the step of:forming at least one longitudinally extending stiffening rib in saidweb.
 32. The method of claim 25, the method further comprising the stepof: forming at least one indentation in said web.
 33. The method ofclaim 25 the method further comprising the step of: forming an endflange in said first flange portion.
 34. The method of claim 25 themethod further comprising the step of: forming a vertically extendingsecond channel in said second flange portion.
 35. The method of claim34, the method further comprising the step of: forming at least onechannel perforation in said vertically extending second channel.
 36. Themethod of claim 34, the method further comprising the step of: formingat least one channel indentation in said vertically extending secondchannel.
 37. The method of claim 25, further comprising the step of:forming an end flange in said second flange portion.
 38. The cold formedstud of claim 1, further comprising: a second cold formed stud having: avertically extending web, said web having a first longitudinal edge anda second longitudinal edge; a first flange portion vertically extendingalong said first longitudinal edge, said first flange portion having avertically extending channel; and a second flange portion verticallyextending along said second longitudinal edge wherein said verticallyextending web of said cold formed stud abuts said vertically extendingweb of said second cold formed stud.
 39. The cold formed stud of claim38 wherein at least one of said vertically extending web of said coldformed stud and said vertically extending web of said second cold formedstud further comprises a plurality of vertical stiffening ribs.
 40. Thecold formed stud of claim 38 wherein said vertically extending web ofsaid cold formed stud is connected to said vertically extending web ofsaid second cold formed stud by way of a fastener.